Voltage control apparatus



Nov. 9, 1943. R. B. HULL VOLTAGE CONTROL APPARATUS 1941 '2 Sheets-Sheet l Filed March 11 MN a UNB MLOU M vw V m NOV. 9, R B HULL VOLTAGE 'CONTROL APPARATUS Filed March l1, 1941 2 Sheets-Sheet 2 indicain M5 3 ad@ ed., /oa

Patented Nov. 9, 1943 A VOLTAGE CONTROL APPARATUS Raouel B. Hull, Anderson, Ind., assignor to General Motors Corporation, Detroit, Mich., a corporation of Delaware Application March 11, 1941, seria1No.3s2,7s9

Coi. 17a-239i 2 Claims.

This invention relates to electrical systems for varying voltage impressed upon an energy translating device, and more particularly to a system which provides an infinitely `variable control of D. C. voltage without the use of an instrument such as a rheostat having contacts which are subjected to wear. This is accomplished by controlling a D. C. voltage which is obtained by rectification of an A. C. voltage through the use of rectier tubes. This invention relates to apparatus for testing the performance of powerdriven, energy-translating devices, such as electric generators at various speeds. Heretofore, when testing generators for example, it has been the practice to connect the generator with a D. C. motor and to vary the speed of the motor by means of a rheostat. The number of different speeds at which the generator may be operated is limited by the number .of contacts on the'rheostat; and the durability of the testing apparatus is limited by the life of the rheostat contacts. When it is considered that a single testing apparatus may be required to test a large quantity of generators during a given period, it is clear that the rheostat will require frequent replacements.

It is therefore an object of the present invention to provide testing apparatus by which the speed of the generator or other device to be tested may be operated at an infinite number of speeds between certain limits, the speed being varied without the use of a rheostat or other speed controlling device having contacts subject to deterioration. It is a further object to simplify the control of the testing apparatus in order to reduce the time consumed by testing. In the disclosed embodiment of the present invention, I provide a constant speed prime mover (preferably an electric motor) connectible with a power shaft (to be coupled with the generator or other device to be tested) by means of an eddy current clutch upon which an infinitely variable voltage (infinitely variable between certain limits) is impressed by adjusting the movable cores of variable inductive reactors included in a voltage controller of the type which controls D. C. voltage obtained by the rectification of an A. C. voltage through the use of rectifier tubes of the thyratron or trigger type.

By means of adjustable reactors an linfinitely variable control of the phase relation between the grid voltage and the cathode voltage of the tubes is obtained over a wide range. By varying the phase relation the point in the A. C. wave in the anode circuit at which the tube hres can be varied. Consequently, the D. C. output voltage obtained by rectiiication of alternating current can be varied over a wide range, the increment of variation being as small or as large as desired.

More specifically, the present invention includes a control monitor having a manually operable handle which, on being moved away from zero speed position causes the source of variable D. C. voltage to be connected ,with the eddy current clutch and theV voltage applied to the clutch to be increased as the handle is moved away from zero speed position. As the voltage applied to the clutch increases, the speed of the power shaft driven by the prime mover, and hence the speed of the generator being tested, increases. When the control monitor handle is moved in the opposite direction, the voltage of the D. C. source is decreased and the source is disconnected from the clutch and a brake is `rendered operative to stop rotation of the power shaft. l'

Further objects and advantages of tle present invention will be apparent from the following description, reference being had to the accompanying drawings wherein a preferred embodiment of the present invention is clearly shown.

In the drawings:

Fig. 1 is a wiring diagram of an embodiment of the present invention.

Fig. 2 is a plan view (with the cover removed) of a manually operated control monitor for varying the angle of phase shift between the grid ,voltage and the cathode voltage' oi the rectifier tubes.

Fig. 3 is a side viewv thereof with cover and one of the reactors in section.

Fig. 4 is a sectional view on line 4 4 of Fig. 2.

Figs. 5 and 6v are sectional views respectively on lines 5-5 and 6-6 of Fig. 3.

Fig. 7 is a fragmentary view showin-g the manner of hinging certain .parts of the brake of the control monitor.

Fig. 8 is a diagram showing the manner in which the control monitor varies the phase angle between the grid voltage and cathode voltage.

Referring to Fig. 1 line wires 20 and 2| from an A. C. source at 220 volts and 60 cycles are connected by switch 22 and fuses 23 and 24 with wires 25 and 26. Fuse 21 connects wire 26 with primary 3l of transformer 30 which is the main power transformer for supplying anode current vto two grid controlled rectifier tubes 60 and 60a for full-wave rectification. Primary 3| is connected by wire 28 and switch 29 with wire 25. The ends of transformer secondary 32 are con, nected by fuses 33 and 34 with contacts 35 and 36 respectively of a relay 40 having movable contacts 4| and 42 for connecting contacts 8l and 38 respectively with other stationary contacts 81 and 88 connected, respectively, with anodes 62 and 82a of tubes 68 and 68a. Movable contacts 4| and 42 are insulated from each other and are connected by a rod 43 with an armature 44 normally maintained in upper position by a spring 45 and attracted downwardly by a coil 46 connected with wire 26 with the contact 48 oi.' a thermal switch 58 having a bimetal blade 48 carrying a contact 41 connected with wire 25 and having a heater' coil 5| connected with secondary 56 of a transformer 55. The thermal switch 58 is so constructed that, when the instrument is at is closed. As will be apparent later the purpose of this is to permit the rectifier tubes 58 and 58a to be heated before becoming connected with secondary 82 of transformer 38. Tubes 68 and 88a are preferably type FG-l'l thyratron tubes.

The closing of switch 28, indicated by the burning of pilot lamp 52, connects wires 25 and 26 with primary coil 54 of auxiliary transformer 55 having secondary coils 55 and 51. The function of secondary 56 is to supply the. necessary power to the cathodes or heaters 8i and 8|a of the rectifier tubes 68 and 88a having grids 63 and 68a connected respectively with variable resistances 64 and 64a each having 10,000 ohms of resistance.

The function of secondary 51 of transformer 55 is to supply power to the phase shifting circuits comprising the apparatus 18 hereinafter called the control monitor." Its function is to vary the phase relation of the grid'voltage with respect to cathode voltage within certain limits. Since the phase-shifting method of grid control is used, an excess of voltage may be applied to the monitor 18. Monitor 18 comprises two variable inductive reactors 12 and 1.4 of Ithe movable core type and two variable resistances or rheostats 1I and 18 connected in bridge to the secondary 51 of the phase shifting voltage transformer 55. The resistors 1| and 13 have a resistance of 5,000 ohms at 70 milliamperes. By means of resistors 1| and 18 the limits of the angle of phase shift of grid voltage with respect to cathode voltage are set, thus determining the range within which lies the point in the A. C. wave in the anode circuit at which the tube fires; and at the same time balancing the anode current through the tubes. The reactors 12 and 14 each have a resistance of 2,400 ohms. Wire 15 connects an' end of transformer secondary 51 with reactor coil 12 having a connection at 16 with resistor 1| and with a wire 1.1 leading to resistance 64 and grid 88. Wire 18 connects an end of transformer secondary 51 with reactor coil 14 having a connection at 18 with resistor 13 and connected by wire 88 with resistance 64a and grid 63a. Wire 8| connects wire 15 with resistor 13. Wire 82 connects wire 18 with resistor 1|.

OneV side of the rectified D. C. line includes wire 88 connected with the center taps of the transformer secondaries 56 and 51, a swinging choke 84, wire 85, wire 86 and contacts |28 and |28. The other side of the rectified D. C. line includes contacts I2| and |24, wire 81 and wire 88 connected with the center tap of secondary 22 of transformer 88. Wire 88 connects wire 88 with a four microfarad filter condenser 88 connected across the D. C. output wires 86 and 81. Condenser 88 `reduces the ripple and raises the output voltage. Variable resistor 8|, which is a 600 ohm. 500 milliampere, bleeder resistor connected in parallel with condenser 88, operates to absorb any high inverse voltage surges from any highly inductive power device which may be connected with wires 88 and 81. The function of the swinging choke 84 is to protect the rectiiler tubes since the, peak charging current of the condenser 88 will reach a value in excess of the rated capacity of the tubes.

By changing the inductive reactance in the bridge circuits which is accomplished by moving the cores 12a and 14a in or out of the reactor coils 12 and 14, a variation of the phase relation of the grid voltage with respect to cathode voltage is obtained over a wide range thus providing an accurate control over the output of the rectiner tubes from zero load to full load depending on the limits set by the resistances 1| and 18. In the diagram Fig. 8, distance horizontally on the line A. C. represents time and the `distances vertically represent voltage. The curve ABC represents one-half of a full wave of alternating current, the distance AC being or the time of one-half cycle of alternating current. The distance from the curve ABC to the base line AC represents instantaneous A. C. voltage applied to the tubes. The line DEF represents, vectorially, an angle of 180. EG or EG represents grid voltage. When the reactor cores 12a and 14a are located so as to occupy all of the central portion within the reactor coils 12 and 14, the grid voltage line EG will coincide with line EF denoting that grid voltage is at 180 phase displacement with respect to the alternating current voltage represented by ABC. At C, this voltage is zero; therefore no output current will be passed by the tubes 68 and 60a. When the reactor cores 12a and 14a are pulled part-way out, the grid voltage changes phase from DEF or 180 to angle DEG. GF represents voltage impressed on the reactors 12 and 14; and DG represents voltage impressed upon the resistors 1| and 18. This means that the tubes 68 and 88a will begin to pass current at point H on alternating current voltage wave ABC. The shaded portion under the line HC represents the output from the tubes 68 and 88a. When the reactor cores 12a and 14a have been nearly withdrawn from the reactor coils 12 and 14 the phase relation between grid voltage and cathode voltage changes to the angle DEG. G'F is the reactor voltage and GD is the resistor voltage. I'his means that the tubes 68 and 68a begin to pass current at point H' on the alternating current voltage curve ABC. The shaded portion beneath the line HBC represents the output of the tubes. It is therefore apparent that the withdrawal of the cores from the reactors changes conditions from one wherein the tubes do not pass current at any time during the alternating current wave to a condition wherein the tubes pass current at all times during the wave. Consequently, the rectified output voltage is increased from zero to the maximum during the withdrawal of the reactor cores andv is reduced as the cores are moved back into the reactor coils.

On the left hand side of Fig. 1, is shown a lever |88 for turning a' shaft |8| carrying a brake drum |82 engaged by brake liningmembers |83 and |84 attached, respectively, to brake bands 85 and |86 which are hingedly connected at |81 and are urged toward the drum by a spring |88 surrounding a screw |88 passing through the bands |85 and |86 and engaging a nut 8. Band |88 carries a contact I i 2 for engaging a contact connected with the wire 25. When the handle is rotated clockwise, the contact H2 will engage the contact in order to connect a magnet coil ||3 with wires 25 and 26. The coil ||3 will be energized and will attract upwardly a solenoid armature |I4 insulatingly connected by a frame ||5 with contacts IIE, |I1, ||8 and H9. Contact I I6 is normally out of engagement with contacts andI2l. Contact ||1 is normally out of engagement with contacts |22 and |23. Contact I I8 normally engages contacts |24 and |25. Contact ||9 normally engages contacts |2|` and |21.

The mechanical connections (not shown in Fig. 1) between the handle |00 and the reactor cores 12a and 14al will be explained in detail later in connection with the description of Figs. 2 to 6. For the present, it is sufficient to state that when the handle |00 is moved counterclockwise, the cores 12a and 14a are being withdrawn from the coils 12 and 14; and, conversely, when the handle |00 is moved clockwise, the cores are being moved into the coils. Therefore, when the handle |00 is moved counterclockwise, the output voltage increases; and, when the handle is moved clockwise, the output voltage decreases.

the switch contacts |II and ||2 are separated; therefore, magnet coil I3 remains deenergized and the switch contacts ||8 and ||9 are in engagement with stationary contacts as shown.

One of the uses of this control of the voltage of unidirectional current is to control the speed of a shaft connected by an eddy current clutch with the squirrel cage rotor of an A. C. motor, such as the motor 200 shown diagrammatically in Fig. l. The frame 20| of motor 200 supports bearings 202 and 203 for a shaft 204. The shaft 204 supports bearings 205 and 206 for a hollow shaft or quill 201 carrying a squirrel cage rotor 208 revolving within a stator 209 comprising a stator core 2|0 and windings 2||. This A. C. motor operates the quill 201 at a constant speed.

nected by wires 223 and 224 with switch contacts |21 and |25. As the voltage impressed upon the clutch coil 2|8 increases, the torque delivered by the clutch from the rotor quill 201 to the shaft 204 increases. Where the shaft 204 is driving a machine, such as a D. C. generator on test, the speed of the shaft 204 increases as the voltage impressed upon the clutch coil 2I8 increases.

One of the uses of the motor 200 is for testing electric generators, for example, direct current generators for use on automotive vehicles. Anautomobile generator is driven by the propelling engine and operates to charge a storage battery and to furnish current for Ylighting and ignition and other automobile accessories. The generator is connected with the battery through a reverse current relay. One of the testsv performed on an automobile generator during its final inspection is to determine at what generator speed it will generate a voltage suiiicient to cause the reverse current relay to close and the charging of the battery to begin. Since the automobile generator is driven at variable speed, it is So long as' the handle |00 is being moved counterclockwise provided with some means of regulation. This may be inherent regulation such as provided by a third brush or other regulation as provided by a current regulator, a voltage regulator or a combination of both. Therefore, another test to be performed on the generator is to determine its output at various speeds, particularly at the highest speed. After these tests have been performed, it is advantageous to bring the generator quickly to rest so that it may be then uncoupled from the shaft 204 and replaced by another generator to be tested. Therefore, it is desirable to bring the motor 200A quickly to rest. By turning the handle |00 clockwise not only will the voltage impressed upon the clutch coil 2|8 diminish but the contacts II| and I|2 will close, thereby energizing the coil ||3 whichwill attract the armature ||4 upwardly thereby causing contacts I I8 and I I9 to move to open position and contacts .The shaft 204 is driven by the motor at a variable ||6 and I|1 to be moved to closed position. This causes the clutch coil 2|0 to be disconnected from the power source and the excitingr coil 23| of a magnetic brake 230 to be connected with the power source. The brake 230 comprises a structure providing north and south poles 232 and 233 acting upon a drum 234 of special alloy iron attached to the shaft 204. This motor 200 with its eddy ,current clutch and eddy current brake, is not perse a part of the present invention, but is disclosed for purposes of illustrating one of the uses of the present invention. The particular motor illustrated is one which is manufactured by the Louis Allis Company of Milwaukee,

Wisconsin.

The 4construction of the control monitor will now be described in detail with reference to Figs. 3 to 6. The shaft which supports the handle |00 is rotatably supported by plates and |3| attached to a base plate |32. Plate |32 supports a bracket |33 which supports pairs of angle bars |34.l Each pair of angle bars |34 supports an external magnetizable core |35 of the reactors 12 and 14. Within each external core |35 is located a reactor coil 12 or 14 surrounding a non-mag-` netizable tube |36. Each tube receives an adjustable core 12a or 14a. As shown in Fig, 2 the cores 12a and 14a are connected by a cross pin |31 which is connected by links |38 and a pin |39 with a lever |40 pivoted upon a rod |4| supported by the plates |30 and |3I. The right end of lever |40 pivotally supports a roller |42 for engaging a camv |43 attached to shaft |0|. The roller |42 is urged toward the cam |43 and the cores 12a and 14a. are urged downwardly by a spring |44 attached at its lower end to a screw |45 fixed to the base |32 and attached at its up per end to a screw |40 fixed to the lever |40. The cam |43 is so shaped as to increase the sensitivity of the control monitor as the handle |00 is moved counterclockwise from Zero speed position. During the first part of the movement of handle |00 counterclockwise from zero speed position the speed increase is relatively slight. This is desirable since it must be known with accuracy at what speed the generator voltage is such that the reverse current relay will close so that charging of thebattery will begin. During the' latter half of th emovement of lever |00 in a counterclockwise direction,A the speed increases rapidly, so that a relatively short movement of the lever |00 brings the generator on test to maximum speed.

The apparatus is housed by a case or cover attached to the base. This case is provided with a slot I5| through which the handle |00a extends.

be provided with a scale of graduation showing the different speeds of the generator being tested corresponding to positions ofthe handle. The movement of the handle is limited by providing the shaft |0| with a cross pin |56 (Fig. 4) the ends of which may strike a stop pin |56 attached to the plate |3|.v

The handle |00 is frictionally held in any position in which it may be set. For this purpose the shaft |0| drives a brake disc |60 engaged by brake shoes |6| and |62 attached to brake bands |63 and |64 which are hingedly connected at |65 and which are urged towards each other by a spring |66 surroundinga screw |61 passing through ends of the bands |63 and |64 and threadedly engaging a nut |68. The band |63 has a straight extension |63a attached by a screw |6312 to base |32. The brake drum |60 is integral with the brake drum |02, shown diagrammatically in Fig. 1.

As shown in Fig. 6, the plate |3| supports a bracket |10 carrying a. nonconducting bushing Ill supporting a screw |12 carrying the contact The screw receives a nut |13 for attaching the screw |12 to the bushing |1|. The screw also receives a nut |14 for securing a wire (not shown) to the screw |12. The brake band |05 shown in section in Fig. 6 supports a nonconducting bushing |80 through which extends a screw |8| carrying the contact H2. Screw |8| receives a nut |82 for securing the screw to the band |05. Screw |8| receives a nut |83 for attaching a wire (not shown) to the screw |8|. Bracket |10 provides a stop member |84 located in the path oi movement of the brake band |05, thereby limiting the extent of separation of the contacts l|2 and when the handle |00 is moved counterclockwise in Figs. 1 and 3. The manner of hingedly connecting the parts of each pair of brake bands will now be described with reference to Fig. 7, which is drawn double the scale of Figs. 5 and 6. One of the brake bands such as |05, is provided with a slot |90 and the other brake band member, such as |06, is provided with a head |9| separated by a narrow neck |92 from the remainder of the band. Slot |90 is slightly longer than the width of the head |9| so that the head may be passed through the slot when the head is 90 from the position shown in Fig. 7. The neck |92, which is slightly greater in Width than the thickness of the band member |06, is received by the intermediate enlarged portion |93 of the slot |80 when the member |06 is turned into the position shown in Fig, 7, after its head |9| has been passed through the slot |90. The band members |63 and |64 are hingedly connected in a similar fashion.

When the handle |00 is moved clockwise, contacts v| I2 and are closed to cause relay coil H3 to be energized thereby causing movable contacts ||8 and ||9 to be separated from their stationary contacts and movable contacts |l6 and ||1 to engage their stationary contacts. This results in disconnection of eddy current clutch coil 2 I8 from the power source, and in the vconnection of the power source to the eddy current brake coil 23|. In using the apparatus to test an automobile generator, the handle |00 oi.' the control monitor is moved counterclockwise to a position which causes the generator to be driven at its cut-in speed, meaning the speed at which the generator begins to charge a storage battery. The `speed is read from a tachometer connected with the motor shaft 204 or with A portion of the case adjacent the slot I 6| may the generator shaft. The current output is read from an ampere meter connected between the generator and the battery. The handle |00 is moved successively into positions such as to cause the generator speeds to increase to such values that the ampere meter will read successively 7, 10, and 15 amperes, for .exampleyand the corresponding speeds are noted. Finally the handle |00 is moved to such position that the 10 generator output has attained its maximum, and

the speed at which the generator begins to dey velop the maximum amperage is noted. I! the test is completed, the handle |60 is moved backward only sufliciently to cause contacts and l5 ||2 to close, whereupon the brake acts promptly to reduce the generator speed to zero. The tester's time is saved by reducing the time for bringing the generator to rest so that another generator to be tested may be substituted for the one which has been tested. It it is desired to repeat 'any part or all of the test, it is not necessary to reduce the generator speed to zero before starting the test again. In such case, the handle |00 is moved quickly to initial position so that the effect of the brake is minimizedl while contacts and ||2 are closed. 'I'he repeating of any part of the test may be started while the generator shaft is still rotating. 'I'his saves the testers time by not requiring that the generator be brought to rest before the test is repeated.

The base |32 may support the adjustable resistors 1| and 13 in any suitable manner, not shown. The cover or case |50 supports the indicator lamp |52 as shown in Figl 3, and may 35 also support the switch 29.

The advantages of the present system of speed control over the conventional control by a rheostat include ilexibility and durability. Greater iiexibility is present because the control by rheo- 40 stat is limited to the number of taps which the rheostat provides, whereas the positions of the reactor cores are unlimited. Greater durability is present because there are no wiping contacts to wear out as in case of a rheostat.

While the embodiment of the present invention as herein disclosed, constitutes a preferred form, it is to be understood that other forms might be adopted, all coming within the scope of the claims which follow.

What is claimed is as follows:

1. Apparatus for testing a power-driven energy-translating device having a drive shaft comprising, in combination, a power-operated shaft, a magnetic clutch having a winding and operable for variably transmitting torque from the poweroperated shaft to the shaft of the device being tested, said torque depending upon the voltage impressed upon the winding of the clutch, a magnetic brake having a winding and operable to stop rotation of the drive-shaft, the eifectiveness of the brake depending on the voltage impressed upon its winding, means for providing a. variable voltage and having a mechanically movable member, the position of which determines the voltage of said means, a` switch which normally connects the clutch winding with the voltage means and normally disconnects the brake winding from the voltage means and which is operable to cause the clutch winding to be disconnected from the voltage means and the brake winding to be connected with the voltage means,

. and a controller having a movable operating handle and means operated thereby for actuating said member of the voltage means and having means responsive to any substantial 'movement or the handle in the direction'for decreasing the voltage for causing the switch to disconnect the clutch winding from the voltage means and to connect the brake winding with the voltage means and responsive to any substantial movement of the handle in the direction for increasing the voltage for allowing the switch to return to normal status, rapid return movement of the handle to minimum voltage position minimizing the eifect of the brake to permit repetition of the test while the drive shaft of the energy-translating device is still rotating.

2. Apparatus for testing a power-driven energytranslating device having a drive shaft comprising, in combination, a power-operated shaft, a magnetic clutch having a winding and operable for variably transmitting torque from the poweroperated shaft to the shaft of the device being tested, said torque depending on the voltage impressed upon the winding of the clutch, a magnetic brake having a winding and operable to stop rotation of the drive shaft, the effectiveness of the brake depending on the voltage impressed upon its winding, means for providing a variable voltage and having a mechanically movable member the position of which determines the voltage of said means, a switch which normally connects the clutch winding with the voltagevmeans and normally disconnects the brakewinding from the voltage means and which is operable to cause the clutch winding to be disconnetced from the voltage means and the brake winding to be connected with the voltage means and a controller having a movable operating handle and a shaft rotated by the handle, means operated by the shaft for actuating the said member of the voltage means, a switch actuator rotatably supported and frictionally connected with the shaft, stops restricting movement of the switch actuator in either direction, a pair of switch contacts engaged by movement of the switch actuator resulting from any substantial movement of the handle in the direction for decreasing the voltage and disengaged by movement of the switch actuator resulting from any substantial movement of the handle in the direction for increasing the voltage, and an electro-magnet which is energized in response to the closing of said pair of switch contacts to operate the first mentioned switch for disconnecting the clutch winding and for connecting the brake winding with the voltage means, rapid return movement of the handle to minimum voltage position minimizing the effect of the brake to permit repetition of the test while the drive-shaft of the energy-translating device is still rotating.

RAOUEL B. HULL. 

